-
“We just made CNC easier”
Advanced Breakout CardsTable I/O CardsTorch Height Controls
Stepper Control SystemsServo Control SystemHand Controllers
MP1000C-THC SETUP MANUAL
All content Copywrited 2008 by CandCNC. All rights reserved.No
repoduction allowed without permission of CandCNC
CandCNChttp://www.CandCNC.com
Including HLC301 I/O Card, MTA100 I/O Card and THC Sensor card“C
SERIES” Addendum
REV6
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RUN
CP
STEP
DIR
X Y Z
HANDWHEEL
MP1000-THC
MASTER CONTROLLER
UP
DWN
TORCHARC
FAULT
THCSET
STOP HOLD
OVP
Torch Volts
Scaled Pulse MonitorShows real-time status of motor outputs.
Step divide by 500 to 4000
Bright high contrast LED’sReadable across the room
100 % Digital ControlsAllows Presets and/or dynamic changes
while
Cutting
THC Status IndicatorsLarge Bright LED’s
Front Panel DB9Connector for plug-in MPG’s
Front panel buttons can be used as inputs to MACH3OR
Directly connected to ACM-100 control Module Controller can be
placed several feetfrom Power/motor cabinet
Indicator for Charge Pump active
10.062
3.2
66
FIGURE 3
Full two port interface + serialBi-directional communication
with MACH3100% Digital ControlTight integration with MACH3Front
Panel access to MACH3 featuresAvailable in three
configurationsPositive snap-action switchesCharge Pump Active
IndicatorUnit is plug compatible with other quality CandCNC
productsBright LED indicatorsBuilt-in Step & Direction pulse
monitorsAll outputs buffered; all inputs opto isolatedFront Panel
connector for MPG (handwheels) and option switches.Exclusive remote
Table I/O card makes hooking up homes and limits quick and easy.
Optional relay outputs at the table where they belong.All connects
made via standard data cables (DB25 & DB9)Completely self
contained. No external power supplies or wall plug
transformers.Drive voltage for Gecko’s provided.Choice of +5 or Gnd
as drive CommonPC logic and ground isolated from other circuit
voltages.Quality components. Designed and built in the USA.
Voltage control to + - 1 voltUsable with hand or machine
torchesIncludes Arc Good sensor for machines not equipped with that
signal.Presetable volts from panel or MACH3Operate the THC from the
panel or MACH3Two separate preset ranges for Regular and Fine
CutOn-the-fly push button adjustmentLast setting retained on power
down (both preset ranges)Advance Digital Height Controller responds
thousands of times per secondInterface to presets table in MACH3.
Select your material from a list.Multiple profile settingsOptimized
for use with touch-n-go surface sensingCompatable with
SheetCAMBright LED readoutEasy to use controls.
THC Features
Basic Features
INTRODUCING THE MP1000 Master Control Unit
-
PO
RT 1
PO
RT 2
SEN
SO
R
CAR
D
SER
IAL
AXIS
I/O
ON
TAB
LE I/O
110 -125VAC
1 Ph 60H
Z only
15
69
15
69
Sin
gle
9 P
in C
able
inte
rface to the
TH
CS
ensor
Card
OR
VF
D Inte
rface for
Spin
dle
Speed
Sin
gle
Cable
inte
rface to o
ur
uniq
ue
Table
I/O
for
easy a
ccess to
Table
lim
its a
nd R
ela
y o
utp
uts
Sin
gle
Cable
inte
rface to r
em
ote
Pow
er
Supply
and D
rive c
abin
et.
4 full
axis
sig
nals
+ p
ow
er
contr
ol*
Buffere
d o
ut, Isola
ted in o
n tw
o p
ara
llel port
sS
erial P
ort
for
advanced inte
rchange w
ith
MA
CH
3
UN
ITP
OW
ER
SW
ITC
H
RE
AR
PA
NE
LF
EA
TU
RE
S
*P
ow
er
Contr
ol is
an a
dded o
ption u
sin
g C
andC
NC
AC
M m
odule
s
FIG
UR
E 4
TE
ST
TIP
Volts
TE
ST
Button
and
LE
D
-
MP1000C Interface Unit
HLC-301I/O Card
(AXIS I/O)
Has buffers and Isolation for All motor (step & dir)signals
up to 5 axis, Isolated inputs for I/O and
integrated Digitial Torch Height Controller (THC)
Provides quick screws terminal inputs for all tableswtiches,
remote feedhold, E-stop(software) andpass-through for 4 aux relays
(via optional QUAD
RELAY BOX) Test buttons and LED indicators.Isolated UP and DOWN
Buttons for manual
operation of Z while cutting (Oxy-Acet)Connects VIA M-F DB25
cable to rear of MP1000C
Mounted in or near the Plasma Unit, thismodule has the Torch
Relay (triggers the
torch from the software), the Tip Voltspickup/divider circuit,
and inputs for either
dry relay contacts for ArcOK (only available onsome plasma
units) or via a Voltage input from
the Arc OK cicuit in the plasma unit OR viathe Current Sense
Transformer (CT) we provide.
Gives Interface options for the Step & DirectionOutputs of
the MP1000C . Plugs into the rear of
the MP1000C (AXIS I/O Plug) and has connectionsfor screw
terminal interface (up to 4 axis of S&D);
ribbon cable interface to the EZPlug series of GeckoInterface
Cards and interconnect to our SPSC Smart
Conntroller series. Card is normally placed in theControl
Cabinet with the Motor Drives and Power
Supply. Connects via single M-M DB25 cable.
MTA100 Mass Terminaion Card
THC Sensor Card
WHAT COMES WITH AN MP1000C-THC Unit
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The setup of the MP1000-THC involves the installation of MACH3
softwareand some support files on the PC to be used for the machine
controller.While we will guide you through the setup for MACH3 the
MACH3 manualgives more in detail instructions on each feature.
Familiarize yourself withthe controls on the front panel of the
MP1000-THC and with the loading andoperation of MACH3 with the
proper profile. The initial part of this manualis devoted to
getting MACH3 properly installed with the right support filesand
profile to run the MP1000-THC. After you have the software
installedand the cables and satellite cards hooked up you will be
guided through aseries of tests to determine if everything is
working. We ask that you gothrought the setup and manual in the
order presented. If at some point youcannot get the expected
results and check your connections and setupwith no success then
call our tech support person (also the engineer,assembler, tester,
webmaster and marketing guy!) at 903-364-2740. Whilewe work a lot
of strange hours we may not always be available to answerthe call
so leave a detailed message of the problem and how to get in
touchwith you will hear back from one of the staff (me or Jim).
Installation and setup of your MP1000-THC Torch Height
Control.
There are a series of steps you must complete to setup and
interface theMP1000-THC with your PC and Your Plasma torch
?? Install and setup the second parallel port in your PC
?? Setup and configure the first serial port (COM1) on your
PC
?? Install MACH3 software
?? Copy your MACH3 license into the MACH3 main folder
?? Run the install program from the CandCNC disk to load
customscreens and setup files
?? Connect the Five port cables (three 25Pin, two 9 Pin) to the
back ofthe MP1000
?? Connect the THC Sensor Card to the back of the MP1000 but do
notmake any plasma unit connections until later
?? Connect the HLC310 card to the Table I/O port on the rear of
theMP1000
?? Connect the MTA100 Card to the motor drive modules
?? Run a quick series of tests to confirm the ports are working
and thatMACH3 is configured correctly
?? Install the THC Sensor card in/on your plasma unit.
?? Install the Arc Good sensing Current transformer (some
units)
?? Do final checkout.
?? Fire up the machine and cut a test file.
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Installing the second parallel port on your PCMost PC’s do not
have a second parallel port and on newer PCI buss computersyou will
need to install a PCI Parallel Port Card. Make sure the card you
installhas drivers for the version of Windows you are running.
Win2000 drivers may ormay not work in XP (or visa versa). When you
install the card in your computerand turn it back on, it should
find the new hardware and when prompted, youshould use the disk
that comes with the port card to install the correct drivers.There
should be instructions with the card on the proper way to install
the drivers.
NOTE: For newer computers with NO communication ports contact us
to get adual port PCI parallel port expansion card. We have one
that is tested and workswith MACH3
After you install the second parallel port and Windows
recognizes the second(LPT2) port then open the device manager from
the Hardware section underWindows /Control Panel/System and open
the Ports icon and find the LPT2entry. Open that and click on the
resources tab.
Write down the first number in the Input/Output range (DE00 in
this caseabove). We will have to enter that number in the MACH3
setup procedurelater
PC Serial Connection.
In order for the MP1000-THC to communicate with MACH3 to
transfer screensettings you must have it connected to your COM1
serial port on the control PC.Use a straight through DB9 cable (not
an RS232 cable or null-modem cable) forthe connection. Make sure
that you do not have any other device (modem, serial
-
You will have to setup the COM1 serial port in Windows. It
should be setup with9600 baud, 8 bits, no parity, 1 stop bit, no
Flow control.
Testing: We will test the functionality of the com port after we
hook up theMP1000 to the computer.
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Installing MACH3 and the custom MP1000-THC files
The actual installation of MACH3 software will not be covered.
It’s fairly straightforward since the file is downloaded from the
website at http://www.artofcnc.caand the file when clicked on will
take you through an install of the software onyour machine. If you
have problems downloading the file or getting a valid installplease
contact the author at art [email protected] or post a question on
theprimary support list in Yahoo Groups (MACH1MACH2CNC). While we
cananswer questions about the proper interface of our MP1000-THC
with MACH3the actual setup and use of MACH3 on a specific PC may
better be handledthrough the actual software provider or the
support list. Our custom filesprovided on our install disk should
setup the PC to work correctly with theMP1000-THC but be aware that
changes you make to setup parameters after theinstall make changes
to the profile.
We have included a version of the MACH3 Manual on the CD. For
plasmacutting most of the manual information is not needed and if
there is a conflict ofplasma specific setup or procedures (this)
MP1000-THC manual should prevail.
After you have installed MACH3 on your computer reboot and
before loadingMACH3 again, open the main folder on the CD and run
the MP1000-THCinstall.exe file in the directory. It will ask you to
define the Drive and directorywhere you have installed MACH3.
The installer should put the correct files under the right
folders. If you decide todo it manually there is a folder on the CD
called “Manual Install” and foldersunder that. Read the
“Manual_Install.txt” txt file in the Manual Install directory.
Itwill provide you with any notes and tell you the correct files to
install in the correctdirectories.
-
About the MACH3 LicenseYou must copy your MACH3 license
(provided when you purchase a full copyfrom the Mach3 website or
from an authorized dealer) into the main MACH3folder. A MACH2
license will work as well. You can check to make sure yourlicense
is active by re-loading MACH3 after the license copy and opening
theHelp/About and making the “licensed to” line is NOT “Demo”. The
MP1000-THCtorch functions WILL NOT WORK WITH A DEMO copy of the
software. Theother motor drive functions will work. If you cannot
get the THC button to showactive, then check your copy to make sure
the license is there. If you upgradethe version the license will
remain but if you manually remove the MACH3 folderor change it’s
name prior to loading a new copy the license file will have to be
re-installed into the working directory.
Setting up the Port 2 address.Within MACH3 on the Ports and Pins
and Port Setup and Axis Selection tab:
?? Enter the hex address you recorded earlier for your second
parallel port.The actual address you have written down should be
proceeded by a”0X” (Zero, X) so something like DE00 becomes 0XDE00
for the inputvalue (or 0xde00 will work since the value is not case
sensitive)
?? Make sure the “Use Pins 2-9 as Inputs” box is checked
?? If the port 2 address is correct the CP (Charge Pump) LED
should be onwhen MACH3 is not in e-stop mode. If it does not come
on then Port 2may not be working correctly. We have found that some
older ParallelPort add-in cards do not work properly with XP. Make
sure your card hasspecific drivers for the version of Windows you
are running.
-
MP
1000 M
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able
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able
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ab
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ab
le
Sin
gle
DB
25 C
able
Handheld
MP
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Ma
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Inte
rfa
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Blo
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To
Table
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FIG
UR
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-
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Ma
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MP
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er
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oto
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Sin
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Ca
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MP
1000
to P
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& M
otor
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DC
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-
Connecting up the MP1000 Controller box. Take a look at the
block diagramdrawing (Fig 5 THC Installation Manual), that gives an
overview of the controlbox, plasma unit and table. Note that there
are three cables that run from the PCand connect to the THC
Controller box. These are labeled Port 1, Port2 andSerial It’s
important that you connect the first parallel port in the
computer(normally the existing printer port or LPT1 port) to Port 1
on the MP1000 box andthe new port you added to Port 2 on the
MP1000. There are also three othercables that connect three
satellite cards (HLC301MTA100 and THC SensorCard) to the MP1000-THC
as well.
1. Install a DB25 Male to Male extension cable (All pins
straight through)between two parallel ports on the PC to the parts
marked Port 1 and Port2 on the back of the MP1000-THC controller
unit.
2. Install a straight through DB9 cable (not a modem cable) from
your Com1port on the PC to the Serial port on the MP1000-THC
3. Plug the MP1000 into a standard 110VAC to 120VAC 60HZ wall
socket.4. The Step and Direction lights will come up in a random
on/off pattern
(could be all off)5. LED readout may have a value showing the
last test voltage used in final
testing. The MP1000-THC retains the last setting it was using
even afterpower down.
6. Turn the unit off with the power switch on the back.
Installing the HLC301 I/O Card.We have provided a functional
remote breakout card to use as your interface atthe machine to
connect the Home and any limit switches via crimp-onconnectors. The
HLC301 as status LED’s for each signal mounted on the cardand small
test buttons to see and test the switch functions. The HLC301 is
aCandCNC exclusive design and will make wiring and test of any
machine easierand faster. All of the table switch signals are
returned to the MP1000-THC via asingle DB25 shielded cable into
isolated inputs. While the isolators provide ahigh degree of noise
immunity it is not good practice to run any signal cable inparallel
and close proximity of high current wires like the motor drive
cables. Themaximum length we recommend for the card to MP1000
interface is 15ft. Longerlengths may need additional grounding or
noise suppression techniques.
As an option we offer a power output package consisting of four
relays. Theapplication of those outputs are covered later. It is
important that the HLC301 beconnected for any testing since there
is a remote E-STOP set of terminals thatmust be shorted (closed) to
make MACH come out of RESET. You can usethese inputs at the table
to hookup a normally closed (opens when activated)Stop switch. If
you elect not to use it the terminals need a jumper between thetwo
EPO connectors. The MP1000-THC will not come out of e-stop with
theHLC301 card disconnected.
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HOME SWITCH Indicators (On shows switch is active)
HARD LIMITS (Indicator must be ON if hard limits used)*
* Hard Limit connectors are in series on the board. Use Normally
Closed (NC) type switches.Any input not connected to a switch MUST
have jumper wire between the two pins. Hard LimitSensing can be
turned off in MACH2/3 if none are used. If are used the jumpers are
neededon unused inputs.
any
AUX Inputs (NO or NC inputs can be used. Must be setup in
MACH3)
EPO Needs jumper if switch not used
Ta
ble
Mo
un
ted
Em
erg
en
cy O
ff
OP
TIO
NA
L
NO
XHome
FIGURE 11
NO C
ZHomeNO C
YHome
NO C
C
AHome
No
rma
lly C
LO
SE
D S
witch
(Ju
mp
er
req
uire
d if
No
Sw
itch
use
d)
Typ
ica
l C
ase
cu
tou
t fo
r su
rfa
ce
mo
un
tin
g o
r re
ar
mo
un
tin
g is 5
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3”
Scre
w t
erm
ina
ls a
re m
ou
nte
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ack o
f ca
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o w
ire
co
nn
ectio
ns a
rep
rote
cte
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UP1
PW
R
AH
OM
ED
WN
AU
X 1
1
J2
7
1
NC
J2
6J2
5J2
4J2
3J2
2J2
0J1
9
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8J1
7J1
6J1
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4J1
3J1
2J11
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25
LIM
ITS
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Z H
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J5
UP
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1
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ME
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O
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OM
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1
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ST
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S
YH
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OM
E HLC
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TO
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FH
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6 9
51
PLUG
RE
LA
YR
EM
OT
E
LIM
IT
X H
OM
EY
HO
ME
Z H
OM
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HO
ME
TO MP1000
TO Quad Relay
HO
ME
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ITC
AR
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FR
OM
TA
BL
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OR
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or
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to
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Th
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an
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bu
tto
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an
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rom
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ron
t o
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2V
DC
fo
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se
wit
hp
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d o
pto
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tic
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s
To Remote Quad Relay Card
-
Buttons not included with stock MP1000 units
UP
1
PWR
A HOME DWN
AUX 11
J27
1
NC
J26J25J24J23J22J20 J19
J18J17J16J15J14J13J12J11 J4
25
LIMITS
CABLE
Z HOME
J5
UP DWN
+12+12
1
FGND
A HOMEZ HOME
Y HOME
EPO
1ISOLATED
AUX1
1
MACHINE INPUTS
X HOME
TABLE I/O
Jumper any UNUSEDUse Normally Closed [NC]
13
14
1
PLUG
J3
1
D8
CANDCNC
TO TESTPUSH BUTTONS
Y HOMEX HOME B HOME
HLC301
[ESTOP]FHOLD
69
51
PLU
G
RELAYREMOTE
LIMIT
X HOME Y HOME Z HOME A HOME
TO
MP
1000
TO
Quad R
elayHOME-LIMIT CARD
Connection for using the UP and Down during cutting operations
(for oxy-acet)
Two Normally Open PushbuttonSwitches
Up
to
25
’a
wa
y
To use the UP and DWN while cutting manaully youmust check the
“Allow THC UP-DOWN...” box in
MACH configuration
UP and Down test buttons will simulatea hand control
-
REAR PANEL
TABLE I/OAXIS I/O THC / SPINDLE I/O
Panels shown out of case for clearity
Less t
han
25 f
eet
FIGURE 14
MTA100 Expansion Card (Breakout)
Rear Panel of MP1000 Case
See M
TA
100 M
anual fo
r hookup w
ith
modula
r E
ZP
lug C
ard
s a
nd J
um
per
settin
gs
19
1010
9
2
1
J55
1
2
20 19
2 1
J52
1
2
9
1010
9
2
1
1
2
9
1010
9
2
1
S&D CARD
1
2
9
1010
9
2
C1
J50
J7
1
J22
Z - A
9
1010
9
2
1
J55
EX
T
1
2
Z A
D2
5V Source
20 19
2 1
1
RE
V1
J9
MU
LTI-A
XIS
INT
ER
FAC
E
1
D3
D1
11
D6
Drive Common
+5
U5
D5
J52
J3
J4Encoder V
1
2
9
1010
9
2
1
CandC
NC
C1
J2
GND
1
2
9
1010
9
2
1
J19
J34
1
2
9
1010
9
2
Rem
ote Shutdow
n
Port
J8
PC
+5
PC
GN
D
J1J5
RS
AXIS I/O IN
J6
X
B - Y'X - Y
J25J18 J23J20 J24J21
Y
J50
SP
SC
Interface
1
MIN
I-IO IN
D4
+5 +5 GNDDir
ST
EP
Dir
ST
EP
Dir
ST
EP
Dir
ST
EP
(TOP) (BOT)
-
The MTA100 Extension Card install.The MP1000-THC is provided
with a small interface and breakout card that isused to deliver the
Step and Direction signals to the proper inputs on your motordriver
module(s). Note that the connections for step, direction and common
aremarked for each axis. Locate the MTA100 Extension Card close
(within 12”) ofyour motor drives. Connect each signal to the proper
pin. The MTA100 can bemounted inside the chassis where your motor
drive modules and the DB 25 cablerun inside that chassis or the
card can be mounted through a cutout and use thejack screws on the
DB25 board connector to hold it in place. See Figure 14 forideas on
using the MTA100 card in your particular install. For Installs
using theEZPlug Modular Expansion Cards refer to the Specific
produt manual forconnection details. For Units shipped with the
PlazPak or Router Pak ElectronicPackages all connections have been
setup,
The common signal for most Gecko’s is +5 and the MP1000/THC is
shipped withthat as default. If you are running motor drives that
require a ground ascommon there is a jumper inside the MP1000-THC
that can be set to allow itto work with Gnd common drives. See the
MP1000C Addendum Section forjumper locations and settings.
NOTE: You cannot run both +5 and GND common type drives in the
samecontroller IF YOU SET THE MP1000C Polarity Jumper to GND. With
theMTA100 you can select either polarity by the drive connection
(hardwired) or ifusing the EZPLug Gecko Interface Modular cards
each card can be set with adrive common polarity. Do not change the
jumper in the MP1000C unless ALL ofthe drives use common GND. If
you don’t know DON’t CHANGE the polarityjumper in the MP1000C
unless you are told to do so by a CandCNC technicalsupport
person.
.
-
C&CNCMP1000-MB
REV 129
2
1
J3
2
202
19
D6
1
J4
25
131
10
J10
10
9
2
1J1
1
10
9
POWER
PORT1 PORT2
AXIS-IO
MPG FRONT PANEL
MPG/Switch inputs
MPG/Switch inputs
FRONT PANEL
REAR PANEL
Front Panel Interface
Front Panel Interface
Table I/O Card
TABLE I/OAXIS I/O
AXIS I/O
THC / SPINDLE I/O
See next page
ACM-A ACM-BJ7 J5
To route the and Switches and LED’s to port input pinsplug ACM
cable into ACM-B as shown.
To Use STOP and RUN switches and indicators to control
theOptional ACM-100 or PSC650/1500 products plug ACM cable into
ACM-A
STOP RUN
STOP RUN
Panels shown out of case for clearity
SERIAL/RS232
Power LED
ACMCABLE
FIGURE 10
The function of the three bottom front panel switches is
determined by the position of the ACM cable. When plugged into
theACM-A Socket on the MP1000C-MB the Unit is setup to control and
indicate a remote SPSC650/1500 Power Controller. If you
are using the MP1000 with our PlazPak series of Power
Controllers the cable should be plugged into ACM-A
The function of the front panel switches and indicators change
when not used with an ACM Power Control Module. With thecable
plugged into ACM-B (factory default) the switches are connected to
input pins for MACH3 and have the functions listed inTable 1. While
the functions can be changed in MACH3 it is recommended they remain
as setup from the factory. We cannot
support other functions mapped to those switches.
Normally JumperedFrom Factory
EPO ControlledFrom Table I/O Card
THC is upper socketSpindle Speed lower (not used)
Connected to DB9on Front panel
Pin 1
Pin 1 Pin 1
Pin 1
-
NOTCH NOTCHPIN1 PIN1
IMPORTANT NOTE ON INTERNAL PLUGS:
The ribbon cable connectorsmay not have a key to prevent them
from being plugged in backwards
IF you unplug an internal cable note the stripe or specific
color of the pin 1 wire on the ribbon cablemake SURE you plug it
back in so that the cable is oriented as shown.
Pin 1 stripe
Pin 1 stripe
Stripe goes to side with PIN1
Typical Ribbon reader
X
X
-
Setting the initial Steps per Unit in MACH3 motor tuning.Every
table will have different Steps per unit, velocity (max speed) and
Accleration settings. Todo testing on the table you must determine
the correct settings for your table. Use the followingmethod:For
Steppers:
1. Determine the number of steps your motors need to make one
full revolution(Normally 200 for most steppers)
2. Determine the ratio of any belt reduction between the motors
and the mechanicaldrive on your table.
3. Determine the drive ratio of your mechanical drive (how far
does the leadscrewor pinion move the load with one revolution.
4. Determine the step frequency of you drives (Full, half,
quarter, 1/8, 1/10 etc)
Now, multiply the motor steps times the drive ratio. A reduction
(most used) is the step downration (like 3:1) so it would be (200 X
3) or 600. If the leadscrew for example has to spin 5 timesto move
one inch multiply the above number by 5 (600 X 5) or 3000. (see
rack and pinionexample if you don’t use leadscrews) We now know it
takes 3000 pulses to move our load 1 inch(obviously if your table
is setup in MM then all of the units will be in MM.)
The last number we have to provide is the step frequency of your
motor drives. Lets say you arerunning in 1/10 th step mode (all
Gecko Steppers use 1/10 microstepping). It will take 10 timesas
many steps to rotate the motor so you also multiply by the step
factor (10 in this case) to get afinal answer of 30,000 steps per
inch.
If your drive is rack and pinion you may find that the
multiplication number is less than one. Forexample where one
revolution of the pinion moves the axis 3.14 inches (1” DP pinion)
we need afractional rotation of the pinion to move 1 inch. The
number will be one divided by the distanceyou move in one pinion
revolution. For the above pinion example you get 1/3.142 or
.3185.NOTE: The distance a pinion moves is a function of the
Diametric Pitch (DP) of the gear times PI(3.1416). The number of
teeth or tooth pitch does not determine the linear travel per
rev.
That becomes your multiplier for the table ratio so for the
above example (given the same beltreduction and steppers) the
answer would look like this:
(200 X 3)(.7353) or 191.082 pulses per inch
The last number we have to provide is the step frequency of your
motor drives. Lets say you arerunning in 1/10
thstep mode. It will take 10 times as many steps to rotate the
motor so you also
multiply by the step factor (10 in this case) to get a final
answer of 191.082 X 10 or 1910.828steps per unit.
You have to do the calculation for each axis and enter the
number in MACH3. Make sure you doa “SAVE AXIS” (button) on each
axis as change them.
For velocity (unless you already know what that should be) enter
a conservative number like 120(120 inches per minute or 120 IPM)
and for acceleration use a number of ½ the velocity
(60inch/min/sec). The acceleration in MACH is set in Inch/sec/sec
so divide the number by 60. Anacceleration of 1 to 3 would be a
good setting to get started.
These numbers and settings are just to get the machine where you
can check the operation ofthe MP1000-THC and should be refined
before actually trying to make any test cuts.
-
For proper tuning of MACH3 please refer to the MACH 3 manual.
The exacttuning of the software is beyond the scope of this
document.
Motor Tuning Screen in MACH3
Testing the MP1000-THC for motor controlAfter you have connected
the Axis I/O pins via the MTA100 to the proper MotorDriver pins and
installed the HLC301 card, you will need to check the
properfunction of those pins. In order to get motion and you need
to have MACH3running with it out of E-stop and the CP LED on the
front panel active (ON).Without CP active, you will not get
motion.
?? Make sure all of the cables are connected.
?? Power up the MP1000C-THC
?? Load Mach3 with the proper profile (MP1000C-THC) and
Screen
?? Hit the Reset button. The LED over the Reset will turn solid
Green
?? The CP LED on the front panel of the MP1000C-THC will turn
solid Green
?? Make sure power is on to your motors. (Customers with the
CandCNCPower Controllers need to get the unit connected to the
Power Controllerand the Power Controller powered up. The DC power
to the motors iscontrolled with the RUN and STOP pushbuttons on the
Front of theMP1000C. You MUST be in RUN mode (Green RUN LED ON) to
getmotion!
?? Use the keyboard arrow keys to jog your machine. Don’t worry
if they jogthe wrong way with the keys or the wrong axis jogs. We
will fix that later.
?? The Step and Direction Monitor on the front panel will
confirm that thesignals are getting out to the MTA100 card. If the
LED’s flash and you arenot getting movement the problem is between
the MP1000-THC and the
-
Setting up the proper axis direction and motor tuningWhile the
Profile file (MP1000-THC.XML) provided with the THC sets up all of
thepins there are several things we don’t know about your machine
and so certainparameters have to be set based on your specific
machine. A good example iswhich axis you may define as X and Y.
There are two ways to swap the axisdefinitions. You can rewire the
motor drives (physically move the step anddirection signals at the
motor drive, or swap the step and direction pins in thesetup of
MACH3. In either case you need to first get your definition into
thesetup. To swap the definition in MACH3, open the Config menu off
of the topmenu bar. Open Ports & Pins and click to open the
Motor Outputs Tab.
Note each axis has a Step and Direction pin. To swap the X and Y
axis simplyswap both parameters. In the example above the step pin
for X would bechanged to 4 and the direction to 5 while the Y would
be 2 and 3 respectively.At this point do not worry if the axis
moves in the wrong direction, simplythat you have the axis as you
define them correct.
The next step is to make the axis movement agree with the DRO
and g-codecommands for that axis. The DRO (Digital Read Out) for
each axis is at the topof the screen. You will need to take MACH3
out of E-stop by pressing the Resetbutton.
1. Jog your machine so the cutting head is away from the limits
(approxcenter of the table is good). Don’t worry if the jog keys
aren’t correct orthat the DRO’s are running in the wrong
direction.
2. If your machine is setup so that one corner is X0,Y0 (lower
left corner?)then all moves from 0,0 should be a positive
number.
-
?? The MDI is a line to allow you to type in direct g-code
commands to makethe machine make specific moves. You don’t need to
have a deepknowledge of g-code to use it for testing.
(Your MDI may look different)
?? When you type in a g-code command it is not case sensitve but
be sure touse zeros’s and not “O’s” for the numbers! At this point
do not worryabout which hotkeys are assigned to a direction.
?? With the machine out of e-stop and power on, type the
following into theMDI Frame:
o Move the screen cursor to the MDI frame and click on it. The
framebackground color should change to yellow meaning it is ready
forinput. No other movement keys work when the MDI frame
isselected.
o G00 X3.0
o Enter key activates command
?? The X axis should move 3 inches in some direction It should
have movedaway from your established X zero and the DRO numbers
should haveincreased. If it did not then you need to reverse the
direction of axistravel.
?? To reverse the direction of any axis open the Ports and Pins/
MotorOutputs and change the polarity of the Dir LowActive setting
for that axis.Clicking the Green Checkmark or the Red X will swap
the definition. RedX is positive and Green Check is negative
polarity.
?? Work with each axis to establish that the movement direction
is correct.Use the MDI frame and change the axis letter from X to Y
then Z. DoNOT change the polarity of the step signal (Should always
be GreenCheckmark) UNLESS you are running Gecko 203V Drives which
takeGND Common signals. 203V Drives need Positive (RED X)
Stepsignals.
-
The final step is to open the Config/System Hotkeys menu and for
eachdirection select the keyboard hotkey you want to use for that
direction oftravel. Now when you press that key the machine should
jog in the properdirection. There are lots of other parameters in
the menus. For moreinformation about them use the MACH3 manual.
A word about homing: It works well to have each axis with a Home
switchand to make that position “0” (absolute zero) for that axis.
The Z with afloating head (discussed later) is an exception.
By having it setup X and Y that way you can always re-establish
you positionon the table. There are circumstances where the DRO
position can vary fromthe actual machine position. An example is if
you do an e-stop during a cut.That form of stop stops the machine
instantly and any code in the look-aheadbuffer is dropped.The only
way to be certain you have not lost position is to home each
axisand reestablish where 0,0 is. The homing in MACH3 is setup
using the menuunder Config/Motor Home/Soft Limits
(Note: the example above is for our machine and may vary for
yours!)
There are several parameters of interest. If you click the Ref X
button next to theX DRO on the Main Screen the machine should start
moving towards the homeswitch for that axis at the speed listed in
the Speed % column for that axis. If itmoves in the wrong direction
flip the polarity of the Home Neg value. You willhave to close the
menu to test the move. Make sure all axis’s move towards thehome
switch for that axis when the button is activated. The machine
shouldmove to the home switch, the switch should make contact and
the movementshould stop and MACH3 will back off the switch slightly
to “un-make” it. You canuse the Diagnostics page in MACH3 to “see”
the LED for each axis come on asthe switch is made and then go off.
All limit LED’s should remain off unless theswitch is activated.
You can test each switch manually by pulling up thediagnostics
screen and manually clicking each switch on your table and
watchingthe LED’s.
If your switch location is not where you want X and Y table
zero’s (0,0) to be thenyou can tell MACH3 what offset you want to
use. Normally the offset will be anegative number since it says
“this axis switch is past the established zero pointon the table”.
The 20% homing speed that is default works well. You do notwant to
home at high speeds as accuracy (repeatability) will suffer.
-
Confirming proper operation
1. With Mach3 running and the MP1000-THC powered up we are going
to gothrough a series of tests that will confirm the unit is
operating .
2. Make sure the MP1000-THC2.set file is the screen for the
MP1000-THCprofile. The CandCNC logo will appear lower left corner
and the MP1000control for tip volt presets will appear in the
center of the screen.
3.NOTE: If the screen is not correct or any buttons or the
background iswrong/missing make sure that the CandCNC directory was
created under theBitmaps directory of MACH3 and that the
MP1000-THC5.set file has beeninstalled in the Main MACH3 folder. DO
NOT USE THE PLASMA.set file thatcomes with MACH3.
4. To confirm proper operation of the serial port, select the
top DRO and typein a voltage number between 50 and 255 volts
followed by a return [Enter]key. Click the “Send to MP1000” button
and the value you just enteredshould appear on the MP1000-THC LED
readout. If there is no changeyou need to recheck the serial port
connection, cable and setup inWindows. Make sure the baud rates and
other control bits are setcorrectly. You should not have to bring
MACH3 out of e-Stop (Reset)mode to move data to the MP1000.
Confirm the operation of the Table I/O card. Make sure it is
connected and thatyou have your table Home switches connected as
shown in the diagram. Openthe Diagnostics screen in MACH3 and watch
the “M Home” group of statusLED’s at the upper right side of the
screen
-
The M1 Home should light up when you manually activate X Home
switch. Itshould be off when the switch is not active. If it is
reversed (i.e. goes OFF whenyou activate the switch but stays on
otherwise) you will need to reverse thepolarity of the switch in
Ports & Pins/ Input Signals. We recommend usingnormally open
(NO) contacts on Homes and Normally Closed (NC) contacts onthe far
limits (if used).The far limits are wired in series by the HLC301
I/O card and it is setup sobreaking the string at any point
activates a hard limit. The hard limits are safetyswitches located
at points on the table to prevent the machine from going pastthe
table travel limits. You can have FAR limits (opposite the 0,0
location of thetable) AND NEAR limits (at points where the machine
would crash on the otherside of the Home switches. Limits are
optional and on stepper based systemsyou could elect to have just
hard stops since the motors can be stalled withoutdamage. Servos
present a different issue. There can be conditions where aservo
will “run away” like if an encoder wire comes loose or becomes
defective.Servos are harder to stall and can self destruct if
allowed to stall and voltage isstill being applied.
There are other options for using table limits besides just
shutting down MACH3.If you are using our SPSC series of AC Power
Control you can actually wire the
hard limits up to the provided inputs in the SPSC Smart Control
module and anactivation of a limit will actually shutdown all power
to the motors….period.Please see the SPSC manual for details.
-
Hooking Up Your Plasma Machine to the MP1000-THC
CAUTION: Portions of this install may include opening your
plasma cuttermachine and attaching wires. MAKE SURE THE UNIT IS
UNPLUGGED PRIORTO REMOVING ANY COVER(S) OR MAKING ANY CONNECTIONS.
Plasma
units have HIGH VOLTAGES present that can be dangerous or
lethal. IFYOU ARE NOT EXPERIENCED WORKING WITH HIGH VOLTAGES, DO
NOTATTEMPT TO INSTALL THIS OR ANY OTHER DEVICE INSIDE YOURPLASMA
UNIT YOURSELF. SEEK PROFESSIONAL HELP.
In order to control your plasma unit, there are three main
connections that needto be made to the plasma unit itself. All of
the following operations are to be
done with the power disconnected from your plasma unit You
shoulddecide if you want to mount the THC Sensor PCB inside your
plasma unit or in asmall external box on the outside of the unit.
You will need access to the DB9connector on the THC Sensor card so
if you mount the card inside, it should beso that the DB9 is
exposed If you cut a small square in the cover or front panelso
that the connector frame will pass through and drill two holes for
the connectormounting holes you can use the connector mounting jack
screws to hold theboard in place. If you use an external box you
will need to provide holes for thesignals listed in the following
steps. Also there is a trigger level adjustment pot onthe front of
the card (VR1) to adjust the level of current that trips the ARC
GOODsignal. Drill an access hole to be able to adjust that pot.
External connectors,hookup wire and external enclosure are not
provided.
THC SENSOR PCB INSTALL:
If your plasma unit does not have an external activate (remote)
torchswitch, you must find the torch activate switch connections.
Normally the torchhandle will have at least one set of small wires
coming from the torch head cableand attaching to a screw terminal
post inside the box. Find the point where thetorch cable enters the
box and identify any small pair(s) of wires that travel up thetorch
head cable. Most machines are setup to be able to change out the
entiretorch head and cable assembly and will have screw terminals
(or a plug) inside tomake that operation easier. Some machines have
different types of specialconnectors to make changing the torch out
easier so you may have to trace backwhere the wires make attachment
to a terminal strip or an internal card. If youmodify any wiring or
circuitry be aware it may void your warranty on the
plasmamachine.
-
To Current Transformeror
Arc Xfr (voltage signal)
Torch Switch Wires
Air and/or tip voltage
Hi Volts
Workpiece Clamp
Torch Switch Wires
DB 9 Connector to THCPort on MP1000-THC
Adjustment forARC OKAYSensivity
WARNING: High voltage present here when plasma unitis in
operation. DO NOT TOUCH!
THC SENSOR CARD DETAILS
NOTE: Probe Switch (J10 & J11) is not used
Some torches will have more than one set of small wiresfor other
sensors in the head. Confirm switch pair with an ohmmeter
while operating the switch (Plasma Unit power OFF)
Good connection to the workpiece with clamp is essentialfor
proper operation of the THC
Chassis Ground
Torch SwitchRelay
Arc
Good
Rela
y
C
J11
K1
J12
J7
C7
R1
R3
L2
Q1
C6
~
L1
R2
Tip
Volts
Torch
Switch
Probe
Switch
Arc
OK C8
J1
THC Sensor Rev 8
EarthTP1
TP2
TP3
TP4
~
~
~-
+
BR1
-
D1
+
J3
D2
+
D5
VR2
J2
J10
J13
J9
J8
-
K2
-
ArcOk V
J2
Q1
R2
TipVolts
Torch
Switch (v)
VR
2
ArcOK
LS1
THC Sensor
J14
J15
J4
TP1
TP2
TP3
TP4
Rev 12
J15
+Standoff
R6
J13
Tip
J12
J11 J10
J5
C3
CAUTION!HIGH VOLTAGE
C2
Insulated
Volts
R1
J3
LS2
C
J11
Arc
Ok V
J12
J7
R1
R3
E
K2
Tip
Vo
lts
To
rch
Sw
itch
VR
2
Arc
OK
C8
D9
THC Sensor Rev 11Sound Logic
TP1
TP2
TP3
TP4
~
~-
+
BR
1
D6
D7
J3
+
J2
J10
J13
-
D8
J1
J5
J4
SW
Arc OKSW
Turns on torch. Connectto terminals to activatetorch or in
parallel withexisting torch swtich
Tu
rns o
n t
orc
h.
Co
nn
ect
to t
erm
ina
ls t
o a
ctiva
teto
rch
or
in p
ara
llel w
ith
exis
tin
g t
orc
h s
wtich
For use with Units that have avoltage signal for Arc Good OR
that use the Current Transformer
Fo
r u
se
with
Un
its t
ha
t h
ave
avo
lta
ge
sig
na
l fo
rA
rc G
oo
d O
Rth
at
use
th
e C
urr
en
tT
ran
sfo
rme
rFor Units that have Dry Contacts
for Arc Good. NOT FOR USEwith Current Transformer
Fo
r U
nits
th
at
ha
ve D
ry C
on
tact
sfo
rA
rc G
oo
d.
NO
TF
OR
US
Ew
ith C
urr
en
t Tra
nsf
orm
er
TIP VOLTS (RAW). Across workclamp andElectrode connections
HIGH VOLTAGE PRESENT WHEN TORCH IS ON!
TIP
VO
LT
S (
RA
W).
Acro
ss w
ork
cla
mp
an
dE
lectr
od
e c
on
ne
ctio
ns
HIG
H V
OLTA
GE
PR
ES
EN
TW
HE
NT
OR
CH
IS
ON
!
DB9 Cable to SENSORplug on MP1000-THC
DB9 Cable to SENSORplug on MP1000-THC
ARC GOODSENSITIVITY
ARC GOODSENSITIVITY
Set at 1/2 range formost setups
Set at 1/2 range formost setups
Use non-conductiveScrew for mouning
on this hole
TorchON
ARCGOOD
J3 JumperON = Normal
Off = 2X
+
-
Use J12 & J13 withCurrent Transformersetup. If the ArcOK(Arc
Good) Signal isDC voltage, then the
polarity marked must beobserved
ArcOK Led will lightwhen ARCOk signalis enough to trip the
relay
Torch ON Led will lightwhen signal from MP1000
Fires the torch
Quick Test: Shorting J4 and J5Should turn on ARC (arc ok)
LED
on front of MP1000 ANDLED on MACH Screen
REV11 BOARDS
REV12 BOARDS
THC SENSOR CARDHOOKUP
Use non-conductiveScrew for mouning
on this hole
-
1. The terminals provide a convenient place to do your
connections. Usecrimp-on spade or round terminals to attach the
wires to the terminalstrips. Make sure the new wires you install do
not touch adjacent metalobjects. On some machines there may be more
than one set of smallwires and are used for sensing tip shorts and
other conditions. To identitythe correct pair use an ohmmeter or
continuity checker across each pairwhile you manually push the
torch head button. When you identify thepair make note of where
they attach. Use #22 to #18 stranded wire(twisted pair) to connect
between the two screw terminals on the THCSensor PCB marked “Torch
Switch”) to the two switch terminals in theplasma unit. There is no
polarity. NOTE: IF your unit has noise filterchokes from the torch
switch wires up to its internal logic card, it isrecommended you
place the two wires to the THC Sensor PCB on theother side of the
chokes from their torch head connection (end closest tothe internal
logic card).
2. If your unit has a tip voltage connection point (i.e. like
the Hypertherm1000 series) ,you will need to use their manual and
suggestions as to howto connect to the two points and run those
wires to the THC Sensor card.Just make sure you use wire that has
insulation rated for at least 400 V.Small signal wire like
telephone wire (UTP) is not rated that high and canarc to nearby
components. The THC Sensor card is designed to take thefull tip
voltage and divide and filter it. Open circuit full tip voltage can
beas high as 300VDC in some machines.
3. If your plasma unit does not have a designated raw tip
voltagemeasurement point, you will need to locate a place inside
the unit whereyou can get one wire onto the Workclamp lead and
another on the heavylead(s) that connect to the torch tip.
a. Note: some machines like the Hypertherm 380 do not have a
singleheavy wire to the Torch tip and instead have a set of
parallelsmaller wires that all terminate into one connector. In the
case ofthe 380 the WHITE wires are the tip volts.
b. You can identify both locations by visually tracing the two
leads asthey come into the box. You should find several
locations/terminalstrips that have connections to these two points
and you can usethose for your sense wire connections. Use
unshielded strandedtwisted wire of #22 to #18 ga rated for at least
400V insulation.
c. Make a connection between the locations you have identified
thattie directly to the two leads (workclamp and torch tip) to the
two“Torch Tip” terminals on J3. Make sure that these wire are
routedwhere they cannot come into contact with hot or
movingcomponents.
-
a. where they cannot come into contact with hot or
movingcomponents.
2. If your plasma unit does not have an “arc good” signal jack
do thefollowing: Make SURE the cord to the plasma unit is
disconnected fromany voltage source. If you have room inside the
unit disconnect one of theAC hot leads prior or following the Main
switch and slide the wire throughthe center of the current sense
transformer like a finger through a donut.There are two connections
on top of the transformer and the large powerresistor supplied
needs to be connected with one lead on eachconnection. In addition
you need to connect a twisted pair wire betweenthe two connections
and the terminal on the board marked “ARCGood”(J6). No polarity.
The transformer is a current transformer andforms its voltage
across the power resistor. This is an AC voltage that werectify and
use to trip the Arc OK circuit /relay on the THC Sensor PCBand use
the isolated relay contacts to signal the parallel port and MACH3.A
good way to mount the current transformer inside the unit is to use
aplastic cable tie and secure it to a nearby bundle of wires or
bracket.
3. If you have a plasma unit that DOES have an Arc Good signal,
you donot need to install the Current Transformer and power
resistor. Just makethe connection to the proper Arc Good terminal.
Some units provide onlyrelay contacts; that will not drive the Arc
OK V input (J12 and J13)relay. The Hypertherm has a provision on
some machines that have ArcGood to make the signal a +24 output on
a valid arc. Their manual coversthe conversion (one jumper) In the
THC Sensor card Testing section thedifferent hookup and testing is
covered .
Note: The term Arc Good is interchangeable with Arc Okay , Arc
Xfer andOkay to Move (Thermal Dynamics)
4. NOTE: IT is ESSENTIAL that the chassis of the plasma unit
have a goodearth ground. Refer to the suggested grounding section
of the diagrams(#####) and provide for a good earth ground close to
the table. A safetyground back to a breaker panel many feet away
may be a good ground forAC frequencies (60hz) but poor for higher
frequencies like plasma noise.Since we are bypassing any high
frequency noise to the plasma chassis, ifit has a poor noise ground
it can actually put noise back into the tip voltsrather than
shunting it away!
-
35 to 100A range Plasma units
Less than 35A Units
Pass one conductor from the AC line straight
through the center of the Current Transformer
Take a full wrap with one wire fromthe AC line.
Wires to ARC OKAYscrew terminals onTHC Sensor Card
Wires to ARC OKAYscrew terminals onTHC Sensor Card
Provided Power Resistoracross terminals
Provided Power Resistoracross terminals
INSTALLATION OF CURRENT TRANSFORMERUsed for plasma units that do
not have
Arc Good (Arc Xfer) signal
-
MP1000 Master Control Box
PLASMAUNIT
THC Sensor Card
PC w/MACH2/3
Tabel I/OCard(limits, homeAux relay)
Controller Cabinet
CNC PLASMA TABLE
Gantry
Ground Rod or Metal polein earth ground
#10 to #4 Ga heavy wire
#10 to #4 Ga heavy wire
Grounding plate
Attached to metalChassi
Do Ground PC or Controllers toEarth Ground Rod. Conrollers will
reference themselves
to power ground through their AC lines
NOT
Note THC Sensor Card shielded cableis not connected to any
ground in the Control box
Ground runs shouldbe less than 10’
Use ground strap to gantry from table
THC500 has built in isolation on all inputs from the tableto
prevent noise transfer and ground loops
Grounding practices to reduce noise and increase safety
-
That concludes the internal connections you will have to make
for your unit.Make sure all leads are insulated and away from
possible physical damage.Double check to make sure there are no
loose connections and that you haveattached/ re-attached any wires
mentioned in the above guidelines.
Replace all covers and safety devices on the plasma unit and
plug the plasmaunit into power with the unit switched off. Turn the
unit on, and make sure theunit works correctly in manual mode.
(i.e. cut a piece of metal by hand). If youhave a machine torch
manually fire the torch from the Torch On button in MACH3
-
The MP1000C has some unique testing circuits that simplify setup
and testing. On if those isthe new Total Isolation Analog circuit
used for Tip Volts feedback. It consists of a linear A/Dand D/A
isolation circuit. The grounds of the MP1000 power are now totally
isolated from theoutside plasma side ground.
As part of this circuit we have added the ability to quickly
test for the presence of Tip Voltvoltage at the back of the
unit.
Once you have the MP1000C-THC connected to all of it’s cards and
have it firing the torchyou can confirm that voltage is getting
from the THC Sensor Card to the Sensor input byobserving the small
Test LED on the rear of the MP1000C-THC close to the Sensor
(DB9)connector. The LED will light up with a proportional
brightness to the applied Tip Volts. If youfire your torch and the
LED does not light you are not getting Tip Volts to the rear of the
unit orthe analog isolation card is not working.
To test the input of the Analog Isolation Card there is a small
recessed test button under theTest LED. You will need a small
screwdriver, or stiff wire (paperclip?) to depress the testbutton.
It takes only a slight pressure to activate the button. DO NOT
PRESS TOO HARD.With the button depressed you should see the LED
illuminate. If it does it means the AnalogInput section is
operational. If you still do not get an LED when the torch fires
(button NOTdepressed) you have a problem in the cable, of at the
THC SENSOR Card.
With the release of the new REV12 THC SENSOR CARD we have added
test LED’s to thecard itself. They indicate the operation of the
two on-board relays. If you are using the cardwith an external
VOLTAGE for ARC GOOD (using our Current Transformer or voltage
fromthe internal logic supply of the Plasma machine) the ARC GOOD
LED will light on the cardwhen it senses the signal. IF you are
using the DRY CONTACTS input for ARC GOOD theLED will NOT light on
the THC SENSOR Card since it bypasses the relay.
The TORCH ON LED will light anytime the TORCH ON Signal from the
computer (TorchButton in MACH or M03 in g-code) is active. To test
your Sensor cardprior to install, attach the THC Sensor card to the
9 pin cable and the other end to the Sensorinput plug on the rear
of the MP1000C-THC. DO NOT MAKE THE CONNECTIONS TO THEPLASMA YET!
Make sure you have the other cards plugged in (HLC301) and have
gonethrough the testing for basic motion control. Turn on the
MP1000C-THC, load the properprofile
Temporarily short the ARC GOOD SW terminals (J4 & J5) input
with a clip lead or jumperwire. This should turn on the ARC LED on
the front of the MP1000C. If it does not, check allof your
connections and make sure you have the proper MACH profile (XML)
loaded. Itshould be the provided on the support CD or off the
Support Site ofCandCNCSupport Yahoo Groups.
Once you have the ARC LED on the MP1000C-THC AND the ARC GOOD
LED in MACH,then turn on the TORCH button in MACH. (MACH
diagnostics screen) should goactive and the Torch Relay on the THC
SENSOR CARD will turn on and the TORCH ON LEDon the Sensor card
will light.
Testing the operation of the THC SENSOR CARD.
MP1000C.THC profile
Output1
(and the MACH setup)
-
With the Torch button on, and the Torch ON Led active on the THC
Sensor card AND theARC LED on the MP1000C the voltage readout on
the TORCH VOLTS readout on the frontof the MP1000C will spool down
close to zero and the Fault LED will light.
With the unit responding to zero volts input (TORCH RELAY ON;
ARC GOOD ON) carefullypush the rear panel test button next to the
Sensor input. The TORCH VOLTS should start tomove from 0 to 128VDC.
It will take a couple of seconds. Hold the test button down until
thereading stabalizes. If should read between 126 and 129 Volts DC
and remain steady as longas the test button is depressed. It the
unit passes this test it indicates:
1. The Analog Isolation card is operational.2. The voltage
reading circuit in the MP1000C-THC is operational3. All the power
supplies in the MP1000C-THC are operational.
Getting ARC OK (ARC GOOD) from your plasma unit.
Most plasma units do not have an easily accessable Arc OK
signal. Check your UserManual for your machine. Some Units offer
the ARC OK as a set of isolated relay contacts(Hypertherm 1000
series and TD with their optional Computer interface card
(expensive).Some units will offer the signal out as a voltage from
5 to 24VDC. Others have no way toaccess the ARC OK signal (almost
all plasma have some form of arc sensing since theirinternal
circuitry uses it) witout digging into the internal circuits.
We supply a Current Sense transformer that measures the AC
current into the plasma unitbut simply wrapping one or more turns
of single HOT AC input wire. The setup andadjustment has been
covered in the Arc OK section. This section is to test the signal
andconfirm it’s operation with the THC Sensor Card. If you have a
unit that has an ARC OKRelay output (”Dry Contacts”) then those
wire should be attached to the two terminals (J4and J5)
IMPORTANT: DO NOT ATTACH THE OUTPUT OF THE CURRENT TRANSFORMER
ORARC OKAY FROM A UNIT THAT OUTPUTS A VOLTAGE TO J4 and J5!. Doing
so willdamage the isolation circuit inside the MP1000C-THC and make
the Arc OK non-operational.AN ARC OK SIGNAL IS REQUIRED TO USE THE
MP1000-THC. If you don’t get one theonly way to cut is to turn off
the THC Button in MACH and use the unit manually.
If you use the Current Sense Transformer (supplied) you must use
the ARC OK V (voltage)Input.J12 and J13. Make sure the resistor is
across the CT terminals as shown. Use thetest procedure outlined in
that section to fire the torch and adjust the sensitivity to make
sureyou are getting arc good. The ARC OK light on the THC SENSOR
card will light (REV 12and higher card) and the ARC Led on the
front of the MP1000C will come on.
On the REV 12 there is a jumper (J3) that when removed increases
the sensitivity 2X for usewith the Current Sense Transformer. For
DC Arc Ok signals from plasma units where theCurrent Sense
Transformer is NOT being used DO NOT REMOVE THE JUMPER on J3
-
FINAL TESTING
1. If you are not using the charge pump enabled, It is possible
for themachine to start up with the port pins in the active state
and fire the torchon bootup. Always have the computer running PRIOR
to turning on yourplasma unit. NOTE: The UP and DOWN inputs are
active low (boxchecked). There is a button to enable the THC in
MACH3. With thetorch head ½ to 1 inch above the material manually
activate the torchfrom the MACH3 console by using the button/hotkey
(Torch On Button)associated with Output1 (normally the spindle ON
or an M03 command inthe MDI). IF the torch lights then go to 4. If
it does not, double check allof your logic and pin setup in MACH3.
Go to the diagnostics page andmake sure the Output1 LED is
flashing.
2. Once you have ignition, you are close to liftoff! Load a test
program forthe plasma. We have included a program that cuts a
series of simplegeometric shapes on a two foot square piece of
material. The feedrate isset for 1/8” material and is 55IPM ; it
may need to be changed for thinnermaterial or other materials
besides steel or other types of machines. Forexample the proper
feedrate for a Hypertherm 1000 (1250, 1650) set to60A with a 60A
tip is about 120IPM. Follow the recommend cut rate foryour
machine.
3. Make sure the THC is turned on (enabled) in MACH3 (THC led
flashing)and you have the pos and neg limits (correctons) set to
logical numbers.Start out with min= -.125 and max=+.5. The THC
function is disabled inthe demo versions of MACH3. Make sure you
have your licenseinstalled and the Help\About screen does not
display “demo” as the user.
4. TURN OFF THE PLASMA MACHINE but leave all cables
connected.Click the RUN button . The code should start to scroll,
the Torch ON ledshould light and the table movement should stop. It
should be waiting forthe Arc Good signal from the plasma. If it
does not stop, check thepolarity of the input for TORCH ON in MACH
3 NOTE: IN MACH2 andMACH3 the “ARC OKAY/ ARC GOOD” is labeled/named
on the input pinas “TORCH ON. (confusing). Check the screen LED
associated with thatinput. It should be OFF (inactive). Once you
have the Arc Good portionworking proceed to 6.
5. Establishing a material Zero. You need to carefully move the
tip to aknown reference point above the surface of the material. If
you do nothave a unit with a floating head, The safest way to
reference the head is toplace a small block of wood below the head
on the top of the material andcarefully lower the tip until it just
touches the block. In MACH2/3 Enter thethickness of the wood
(measure with dial micrometer for precision andmark the number on
the block) into the Z DRO and hit the Enter key tostore the
value.
-
6. Establishing a material Zero with a floating head and sensor
switch. Ifyou have a floating head and sensor switch and the switch
is mapped to the ZHome function in MACH3 simply perform a Reference
move on Z. If you areusing MACH3 there is a location in the MACH3
config to apply a Home switchoffset. You can enter your switch
travel value there and no further moves orinputs are needed.
a. Note to SHEETCAM users. We have provided a special Post
forMACH3 and the MP1000-THC to be used when generating outputfrom
SheetCAM. It has an automatic “touch-n-go” feature thatreads the
traveled distance and once it exceeds 500mm (about 20inches) a Z
reference is performed just prior to the next pierce.This post is
intended for use with the MP1000-THC and a floatinghead setup
ONLY.
b. For non-SHEETCAM users. Mach 3 provides added
THCfunctionality and has inputs for pierce height, initial cut
height , etc.At this point we have not tested those features so
their use isdiscouraged. It is recommend that any references for
the Z whilecutting be edited into the g-code as:
G00 Z.75G28.1 Z.5G92 Z0G00 Z[your switch travel here]G92 Z0G00
Z.5
This should be inserted just prior to the Torch ON (M03) event
atany given pierce point where you wish to re-reference the Z
7. Establishing the starting tip voltage for the cut. The
MP1000-THC has theprovision to preset the tip voltage (and thus the
cut gap) for the cut prior torunning the program. While each brand
of plasma unit is different the tipvolts will typically be in the
range of 100 to 150VDC (Fine Cutconsumables are an exception and
operate at lower voltages and smallergaps). You should find a chart
of recommended voltages fordifferent materials and tips for your
machine. A few volts can make alot of difference. If you are in
doubt, start high and work your way down tothe optimum voltage and
height to prevent crashing the tip into thematerial. You can reload
a value from the MP1000-THC MACH3 screenby typing the value into
the upper DRO ( the one shown below as “144”)and hitting the Enter
key to store it in the DRO THEN hitting the “Send toMP1000” to move
the value into the MP1000. This will be the target valuefor
cutting.
-
8. With the plasma unit powered up and with the Z referenced,
rewind thetest program and with the THC enabled, start the cut
using the RUN (cyclestart) button. The fault light should go out
and the ARC Good light shouldcome on. (see 9 if it does not). The
Up and Down LED’s in MACH2 shouldhave distinct transitions and the
front panel LEDs should track the screenLED’s. The ARC GOOD LED on
the front panel should be on. Note theindicated tip voltage and the
height in the Z DRO. Make sure that the THCDRO in MACH3 (bottom DRO
in the axis DRO group) showing the amount ofadjustment is changing.
This is an incremental value. The Z DRO will change(not as fast as
the THC DRO) and give you an absolute value. If UP orDOWN stays on
you have reached the limit of the values you have set in theMax and
Min (or the head is not adjusting correctly). The best setting
iswhere the head is tracking about .125 above the material (.080
for someunits) and the UP and DOWN LED’s are mostly both off. As
the cut isprogressing note the average voltage at the MP1000 panel
and use the Upand Down switches on the MP1000-THC front panel OR
the UP and Downarrow buttons in the MACH3 screen change the setting
if needed. At the endof the cut the voltage (after the torch is
turned off) the voltage on the LEDmeter of the MP1000-THC will
revert back to the target voltage. If you havechanged it during the
cut it will display the new target voltage. If you do nothave the
recommended cut voltage setting for your machine, you willneed to
observe the gap as it cuts and set it for a position that gives
good cutresults. This could be anywhere from .062 inches to .140
above the materialdepending on the machine. Trial and error is the
only way to get the best cut.
a. Cut quality in plasma is a function of several factors:
?? Clean DRY air.
?? Sufficient and consistent air pressure (typically 65 to
80PSI)
?? Good consumables.
?? Proper cut height (Proper adjustment of THC voltage)
?? Proper Feedrate (cutting speed)
?? Proper settings of the THC Rate and CV settings inMACH2/3
-
If your cut edges are flared in or out check all but the
lastfactor. If your MP1000-THC does not respond fast enough
onuneven (warped/un-level) material you may need to increasethe THC
Speed (percentage of Max Z speed) from 20% to ashigh as 50%. Do not
go much higher than 50% on a stepperaxis, since while the THC has
control of the Z, accel/deccelsettings for the motor are ignored.
If the cuts are jagged oncurves, or the movements of the machine
becomes jerky youmay need to alter the values for Constant Velocity
tuning inMACH2/3. Each machine is different and the values
arepreset for a value that works with most machines but yourresults
may vary. See the section for CV tuning forsuggestions or refer to
the MACH manual for more detail.
1. Setting the Arc Good trip point. If you are using the
supplied CurrentTransformer for Arc Good sensing, It is possible
that you will need toadjust the trip point of the ARC GOOD circuit
by adjusting it with VR1 onthe THC Sensor Card. Turn the control
fully counterclock wise anddetermine it if lights the ARC GOOD led
on the front of the MP1000 whenfiring the torch against the metal.
(doing a normal pierce). If it does notlight it is possible your
torch is a smaller unit and you need to change thevalue of the
power resistor at the Current Transformer from the 15ohm to
a 30 ohm. Make sure you disconnect the plasma until fromany
power BEFORE making any of the listed modificationsUnits smaller
than 35A ratings (especially if they are wired and runningfrom
230VAC) need the higher value of resistor in addtion on some
unitsyou will need to loop the AC line going through the CT hole
two or moreturns. (See diagram #####) This increases the developed
voltage peramp of current. The new REV12 THC Sensor Card has a
jumper (J3)when REMOVED doubles the voltage from the CT transfomer.
You mayneed to do one or all of the changes to get a valid ARC
Good.
2. Once the Arc Good LED comes on you should slowly increase the
settinguntil it ceases to turn on with a valid pierce or you hit
the stop. In eithercase back the pot off of the max setting so you
are about 2/3’s of the waybetween the Min setting and the Max
setting. The goal is to have the ArcGood fire when there is a valid
arc under most of the current settings youwould use with your
machine but NOT when it just idling or firing the torchin the
air.
-
Setting the Tip volts from a stored table in MACH3.
A feature of the new MP1000-THC and MACH3 integration is that
you candefine a table of Material/voltage values that an operator
can pick from.We include a default table based on the recommended
settings for aHypertherm 1000. You may want to modify the settings
for you machineor add new ones. To do so you need to use a simple
text editor likeNotepad to open the TorchVolts.txt file in the main
MACH3 folder. It willlook like this:
-
It will hold up to 200 name-value pairs. Each name and value is
delimitedby a carriage return for example the 16Ga Steel is the
name, and 134 isthe tip volt value associated with it. The file has
to be named TorchVoltsand be a standard text (.txt) file.
When the operator clicks on the Table Val button the material
listing willbe displayed and when a material is selected the value
is moved into theTable Value (Bottom) DRO. That does not move it to
the MP1000. Youmust move the table value into the Tip Volt DRO
(top) using the Xferbutton
then load the value to the MP1000-THC using the “Send to MP1000”
Button.Only the value that is in the top DRO gets transferred to
the MP1000-THC
-
ADDENDUM SECTION
Setting The Step and Direction Pulse RatioFront Panel Function
ChartInternal Cable Routing DiagramUsing Output Relay
(Option)Auxilary Connector PinoutsPINOUTS Port1 & 2 DB25
(rear)Using the MP1000 RUN and STOP front panel buttons for
Power Controller controlJumper Setting Addendum for new “C
Series” MP1000-THC’s
-
U5
2=1/1000
J5
1
J6
BR1
SW1
SPINDLE
21=1/500
THC 4=1/4000
TIPVADJ
TP1
4
1
20
X Select
1
1
J4
J2
J1
J7
1 2
3=1/2000
3 4Y Select1 2 3 4
Z Select
10
9
2
1
1 3
CandCNC
MP1000-FP
REV 1
9
10 J9 2
11 J8
J10
Step & Dir Monitor Divide Ratio
Front Switch Interface jack
Dual SpindleExpansion Plug
Mother Board Connection PlugCalibration
(Factory Set)
Danger! Possible High Voltage Section
FRONT PANEL BACK (top of PCB)
To set the divide ratio for each axis there are Jumper Blocks
for each monitoredaxis. The actual ratio is a function of personal
preference but normally a number of about 10:1for the given
frequency works well. Here is an example:
n the software your step pulse rate (steps per unit) is set to
8000. If you divide 8000by 1000 (second option jumper position) you
will see 8 pulses per second. Setting the optionjumper to the third
position you will see 4 pulses per second. The numbers don't have
to beeven and the output is just for visual confirmation of the
step pulses.
If your pulse rate is higher or lower than 8000 then you may
want to set the divide ratiodifferently. The options are designed
to provide a good visual indication of step pulses from aslow as
500 up to 45000.
Units are shipped with all of the jumpers installed on the /500
(divide by 500) position.
Select the jumper then powerthe computer up and the . Jog your
machine at full speed and note the Step flash rate.If it is too
fast (on most of the time) or too slow (off most of the time, then
select another divide
option.
(J1,J2 & J4)
Assume i
,
ratio
Do not change the jumpers with the powered up.MP1000MP1000
SETTING THE STEP AND DIRECTION MONITOR PULSE RATIO
ACM Cable Plug
FIGURE 7
-
X Y Z
UP
DWN
DWN
UP
ARC
FAULT
TORCH ON
STEP
DIR
RUN
RUN
FHold STOP
STOP CP
FRONT PANEL FUNCTION CHART
FIGURE 8
WITH ACM-100 orSPSC Power Controller
WITHOUT ACM-100 orSPSC Power Controller
RUN LED
RUN SWITCH
AUX SWITCH
STOP LED
STOP SWITCH
Power ON to Motors
Power OFF to Motors
Activate Power to Motors
Deactivate Power to Motors
Program Feedhold
Charge Pump Actie
Same as RUN Button in MACH3
Table 1
Program Feedhold
EPO / EStop Active
E-Stop (Software)
ACM Cable inACM-A
ACM Cable inACM-B
Default setup from factory
THC Section
-
C&CNCMP1000-MB
REV 12
Gnd
9
2
1J3
2
9
5
U4
20 2
19
D6
1
J4
25
13
14
J7
ACM-BACM-A
10
C12
J1025
SKT
10
9
2
1 J1
1
J5
10
9
REG2
POWER
PORT1
PORT2
AXIS-IO
MPG FRONT PANEL
MPG/Switch inputs
MPG/Switch inputs
FRONT PANEL
REAR PANEL
Front Panel Interface
Front Panel Interface
Table I/O Card
TABLE I/OAXIS I/O
AXIS I/O
THC / Analog I/OCARD
See instr
uctions for
corr
ect plu
g
See next page
Panels shown out of case for clearity
FIGURE 9
-
1 5
6 9
DB9 P (Male Pins)
+5V
+5V
MPG2(A)/SW1MPG1(B)
MPG2(B)/SW2MPG1(A)
MPGSWITCH
Gnd SW3
HANDWHEEL DB9 PINOUT
NOTE: Some functions appear onmore than one connector.
MP1000 Connector Pinouts (DB9’s)
15
Female Connector(numbering opposite Male)
Flo
ating
TH
C G
nd
Z H
om
e (
Port
2 -
Pin
13)
Arc
OK
Arc
OK
LE
D
NC
6 9
+12V
Torc
hT
rigger
Sw
itch R
ela
y
Torc
hT
ip V
olts
Torc
hT
ip V
olts
All Connectors viewed from the front
THC SENSOR CARD Connector (Rear)
-
PINOUTSC SeriesTABLE 2
Port Pin NAME Prev Func REV C Func Iso FOR
1 1 IO-1 DB9 FP IO-1 Y K5
1 2 Xstep AxisIO-2 AxisIO-2 N to MTA100
1 3 Xdir AxisIO-3 AxisIO-3 N to MTA100
1 4 Ystep AxisIO-4 AxisIO-4 N to MTA100
1 5 Ydir AxisIO-5 AxisIO-5 N to MTA100
1 6 Zstep AxisIO-6 AxisIO-6 N to MTA100
1 7 Zdir AxisIO-7 AxisIO-7 N to MTA100
1 8 Astep AxisIO-8 AxisIO-8 N to MTA100
1 9 Adir AxisIO-9 AxisIO-9 N to MTA100
1 10 E-Stop IN HCL310-20 Y EPO
1 11 Xhome TableIO-14 HCL301-14 Y Input
1 12 Yhome TableIO-15 HCL301-15 Y Input
1 13 Zhome TableIO-16 HCL301-16 Y Input
1 14 IO-2 TableIO-12 HCL301-12 Y K2 (1A)
1 15 Ahome TableIO-17 HCL301-17 Y Input
1 16 IO-3 TableIO-11 HCL301-11 Y K3 (15A) A
1 17 IO-4 TableIO-10 HCL301-10 Y K4 (10A) B
1 18 Gnd PCGND PCGND
1 19 Gnd PCGND PCGND
2 1 T-Relay THCSensor- THCSensor- TorchRelay
2 2 Limits TableIO-1 HCL301-1 Y input
2 3 Feedhold TableIO-2 HCL301-2 Y input
2 4 FP-SW-RUN FP/MACH HCL301-22 Y ACM-A/B
2 5 FP-SW-STOP FP/MACH HCL301-23 Y ACM-A/B
2 6 UP IN/THCPlug HCL301-21 Y Dual use
2 7 DOWN IN/THCPlug HCL310-24 Y
2 8 ARC Good IN/THCPlug THCSensor- Y THC Sensor
2 9 FP-DB9-7 MPGsw MPGsw N MPG IN
2 10 FP-DB9-5 MPGsw2 MPGsw2 N MPG IN
2 11 FP-DB9-6 MPGa MPGa N MPG IN
2 12 FP-DB9-2 MPGb MPGb N MPG IN
2 13 FP-DB9-4 MPG2A MPG2A N MPG IN
2 14 Aux\out TableIO-9 Bstep/Axis-18 N
2 15 FP-DB9-9 MPG2B MPG2B N MPG IN
2 16 SpinDir/BDIR N/A SpS Dir/B Dir 5th Axis Dir
2 17 Cpump Out Out N Watchdog
MP1000C PinOuts
Notes: Pins in Yellow are new with MP1000C AND HCL301 Combo.
Relays
now moved to Quad Relay Card (Green). FP-Run & FP- Stop
inputs can be
used as AUX inputs if MP1000C is used with any PSC or SPSC
products.
-
Jumpers shown in their default settings for operation
withCandCNC Power Control Units
JUMPER DETAILS FOR MP1000 “C SERIES” cards
Move
AC
M c
able
fro
mA
CM
-Ato
AC
M-B
for
NO
N-C
andC
NC
Pow
er
Contr
olle
rs
For NON CandCNC powerControl Units jumper J14
to pins 1-2
All other jumpers stay in default condition
NOTE Your C Series MP1000 will be jumpered to work with the
configuration you order. If youorder a Package Deal with a Power
Controller (Plazpak series) then the jumpers will
be set for use with that product.
ISO21
ISO
21
10
J14
EA
CM
-B
1
10
C&
CN
C
MP
1000C
-MB
RE
V 1
4
1
Q9
16
13
TA
BLE
IO
C
9
SIP
10-2
.7K
POWER
R10
J1
2
1
R4
U23
E
2
1
C1
FR
ON
TP
AN
EL
1
9
2
1
1A
CM
-A
R
J3
26
D8
R6
R2
R9
2
Q4
R11
2.7
K X
10
16
4.7
K
POWER
C8
SIP
5
SIP
6
MP
G
E
15
C5
C10
P1
SK
TS
KT
1KC21
Q6
J22
SK
T
SERIAL
SK
T
U4
15
C7
SIP
1
2
D7
R3
2
E
1
J3
12
1
POWER IN
Q1
J2
13
1
EPO Jumper
12
1
CP
Jum
per
U24
9
J4
J4
SK
TS
KT
GND
R23
R24
AX
IS-I
O
U21J7
R22
J5
PORT1
AC
M-B
C
1
AC
M-A
U20
Q7
C
J1
10 10
PORT2
SIP
2R7
R5
SIP
3S
IP3
MP
G
R1
J5
C9
1
SPSC
10KU6
101
U25
U25
100
1
J8
10
J10
10
D5
C6
R8
+12 FLT
U22
U22
Q2
D6
C11
+5 PC
R13 1K
1
COMMON POL
R16
R14
NSPSC
CP
NCP
+5
SIP
64.7
X 5
(6)
Charge PumpDisable
Jumper to NCP end
See instructionsCommon Pol should
stay on +5 unless you arerunning ALL drivesat common ground.
